INPUT SHAFT REASSEMBLY


  1. INSTALL INPUT SHAFT FRONT BEARING


    1. A0138A6E05

      Using SST and a press, install a new input shaft front bearing to the input shaft.

      SST
      09515-10010

  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING


    1. A01375B

      Coat the 3rd gear needle roller bearing with gear oil, and install it to the input shaft.

  3. INSTALL 3RD GEAR


    1. A0136X3E01

      Coat the 3rd gear with gear oil, and install it to the input shaft.

  4. INSTALL 3RD GEAR SYNCHRONIZER RING


    1. A0138E8E01

      Coat the 3rd gear synchronizer ring with gear oil, and install it to the 3rd gear.

  5. INSTALL NO. 2 TRANSMISSION CLUTCH HUB


    1. A0136TY

      Install the No. 2 transmission hub sleeve to the No. 2 transmission clutch hub, and then install the 3 No. 2 shifting keys and the 2 No. 2 shifting key springs.

      Note

      Assemble the No. 2 transmission hub sleeve and the No. 2 transmission clutch hub in the correct orientations shown in the illustration.

    2. A0138EME03

      Using SST and a press, install the No. 2 transmission clutch hub set to the input shaft.

      SST
      09506-35010

      Note


      • Install the No. 2 transmission clutch hub set in the correct orientation shown in the illustration.

      • When installing the No. 2 transmission clutch hub set, align the cutout of the No. 2 transmission clutch hub with the protrusion of the 3rd gear synchronizer ring.

  6. INSTALL NO. 2 CLUTCH HUB SETTING SHAFT SNAP RING


    1. A0136IDE05
      Text in Illustration
      *a Mark

      Select a new No. 2 clutch hub setting shaft snap ring that allows the minimum axial play.

      Standard axial play
      0.1 mm (0.00393 in.) or less.
      Snap Ring Thickness
      Part No. Mark

      Thickness

      mm (in.)
      90520-32014 A 2.28 (0.0898)
      90520-32015 B 2.34 (0.0921)
      90520-32016 C 2.40 (0.0945)
      90520-32017 D 2.46 (0.0969)
      90520-32018 E 2.52 (0.0992)
      90520-32019 F 2.58 (0.1016)
    2. A01369CE01

      Using a snap ring expander, install the No. 2 clutch hub setting shaft snap ring to the input shaft.

      Note

      Do not damage the journal surface of the input shaft.

  7. INSPECT 3RD GEAR THRUST CLEARANCE


    1. A0137WVE01

      Using a feeler gauge, measure the 3rd gear thrust clearance.

      Standard clearance
      0.10 to 0.35 mm (0.00394 to 0.0137 in.)
      Maximum clearance
      0.35 mm (0.0137 in.)

      If the clearance is more than the maximum, replace the No. 2 transmission clutch hub, 3rd gear or input shaft. Replace the part or parts determined to be the most likely cause of the problem.

  8. INSPECT 3RD GEAR RADIAL CLEARANCE


    1. A0138MVE01

      Using a dial indicator, measure the 3rd gear radial clearance.

      Standard clearance
      0.015 to 0.058 mm (0.000591 to 0.00228 in.)
      Maximum clearance
      0.058 mm (0.00228 in.)

      If the clearance is more than the maximum, replace the 3rd gear, 3rd gear needle roller bearing or input shaft. Replace the part or parts determined to be the most likely cause of the problem.

  9. INSTALL 4TH GEAR SYNCHRONIZER RING


    1. A0137LXE01

      Coat the 4th gear synchronizer ring with gear oil, and install it to the No. 2 transmission clutch hub.

  10. INSTALL 4TH GEAR BEARING SPACER


    1. A0137ZYE01

      Coat the 4th gear bearing spacer with gear oil, and install it to the input shaft.

  11. INSTALL 4TH GEAR NEEDLE ROLLER BEARING


    1. A0138JT

      Coat the 4th gear needle roller bearing with gear oil, and install it to the input shaft.

  12. INSTALL 4TH GEAR


    1. A0138HKE01

      Coat the 4th gear with gear oil, and install it to the input shaft.

  13. INSTALL 5TH GEAR THRUST WASHER BALL


    1. A0135ZCE01

      Install the 5th gear thrust washer ball to the input shaft.

  14. INSTALL 5TH GEAR THRUST WASHER


    1. A0136F5E01

      Coat the 5th gear thrust washer with gear oil, and install it to the input shaft.

  15. INSTALL 5TH GEAR SHAFT SNAP RING


    1. A0138BSE03
      Text in Illustration
      *a Mark

      Using the table below, select a new 5th gear shaft snap ring that makes the thrust clearance of the 5th gear thrust washer less than 0.1 mm (0.00393 in.).

      Snap Ring Thickness
      Part No. Mark

      Thickness

      mm (in.)
      90520-29049 1 2.28 (0.0898)
      90520-29050 2 2.34 (0.0921)
      90520-29052 3 2.40 (0.0945)
      90520-29053 4 2.46 (0.0969)
      90520-29054 5 2.52 (0.0992)
      90520-29055 6 2.58 (0.1016)
    2. A0136AKE01

      Using a snap ring expander, install the 5th gear shaft snap ring to the input shaft.

      Note

      Do not damage the journal surface of the input shaft.

  16. INSPECT 4TH GEAR THRUST CLEARANCE


    1. A0138IVE01

      Using a dial indicator, measure the 4th gear thrust clearance.

      Standard clearance
      0.10 to 0.55 mm (0.00394 to 0.0216 in.)
      Maximum clearance
      0.55 mm (0.0216 in.)

      If the clearance is more than the maximum, replace the No. 2 transmission clutch hub, 4th gear or 5th gear thrust washer. Replace the part or parts determined to be the most likely cause of the problem.

  17. INSPECT 4TH GEAR RADIAL CLEARANCE


    1. A0137SEE01

      Using a dial indicator, measure the 4th gear radial clearance.

      Standard clearance
      0.015 to 0.058 mm (0.000591 to 0.00228 in.)
      Maximum clearance
      0.058 mm (0.00228 in.)

      If the clearance is more than the maximum, replace the 4th gear, 4th gear needle roller bearing or input shaft. Replace the part or parts determined to be the most likely cause of the problem.

  18. INSTALL 5TH GEAR BEARING SPACER


    1. A0138A1E01

      Coat the 5th gear bearing spacer with gear oil, and install it to the input shaft.

  19. INSTALL 5TH GEAR NEEDLE ROLLER BEARING


    1. A0136QN

      Coat the 5th gear needle roller bearing with gear oil, and install it to the input shaft.

  20. INSTALL 5TH GEAR


    1. A0135TQE01

      Coat the 5th gear with gear oil, and install it to the input shaft.

  21. INSTALL 5TH GEAR SYNCHRONIZER RING


    1. A0136NKE01

      Coat the 5th gear synchronizer ring with gear oil, and install it to the 5th gear.

  22. INSTALL NO. 3 TRANSMISSION CLUTCH HUB


    1. A01373YE01

      Install the No. 3 transmission hub sleeve to the No. 3 transmission clutch hub, and then install the 3 No. 3 shifting keys and the 2 No. 3 shifting key springs.

      Note

      Assemble the No. 3 transmission hub sleeve, 3 No. 3 shifting keys and the No. 3 transmission clutch hub in the correct orientations shown in the illustration.

    2. Place the 5th gear synchronizer ring on the 5th gear, and align the synchronizer ring slots with the No. 3 shifting keys.

    3. A0136CJE03

      Using SST and a press, install the No. 3 transmission clutch hub set to the input shaft.

      SST
      09515-10010

      Note

      Install the No. 3 transmission clutch hub set in the correct orientation as shown in the illustration.

  23. INSTALL INPUT SHAFT REAR RADIAL BALL BEARING


    1. A0137KHE03

      Using SST and a press, install a new input shaft rear radial ball bearing to the input shaft.

      SST
      09515-10010

  24. INSPECT 5TH GEAR THRUST CLEARANCE


    1. A0137MUE01

      Using a dial indicator, measure the 5th gear thrust clearance.

      Standard clearance
      0.10 to 0.50 mm (0.00394 to 0.0196 in.)
      Maximum clearance
      0.50 mm (0.0196 in.)

      If the clearance is more than the maximum, replace the No. 3 transmission clutch hub, 5th gear or 5th gear thrust washer. Replace the part or parts determined to be the most likely cause of the problem.

  25. INSPECT 5TH GEAR RADIAL CLEARANCE


    1. A0137C1E01

      Using a dial indicator, measure the 5th gear radial clearance.

      Standard clearance
      0.015 to 0.058 mm (0.000591 to 0.00228 in.)
      Maximum clearance
      0.058 mm (0.00228 in.)

      If the clearance is more than the maximum, replace the 5th gear, 5th gear needle roller bearing or input shaft. Replace the part or parts determined to be the most likely cause of the problem.